test: add MLS and MeshEnvelope size measurement tests

- measure_mls_wire_sizes: KeyPackage, Welcome, Commit, AppMessage sizes
- measure_mls_wire_sizes_hybrid: same with post-quantum mode
- measure_mesh_envelope_overhead: MeshEnvelope overhead for various payloads

These tests print actual byte sizes to inform constrained link
feasibility planning (LoRa SF12, MLS-Lite design).

crates/quicprochat-core/src/group.rs

@@ -1079,4 +1079,96 @@ mod tests {
             "send_message before join must return an error"
         );
     }
+
+    /// Measure actual MLS artifact sizes for mesh planning.
+    /// These numbers inform the MLS-Lite design and constrained link feasibility.
+    #[test]
+    fn measure_mls_wire_sizes() {
+        let creator_id = Arc::new(IdentityKeypair::generate());
+        let joiner_id = Arc::new(IdentityKeypair::generate());
+
+        let mut creator = GroupMember::new(Arc::clone(&creator_id));
+        let mut joiner = GroupMember::new(Arc::clone(&joiner_id));
+
+        // 1. KeyPackage size
+        let kp_bytes = joiner.generate_key_package().expect("generate KP");
+        println!("=== MLS Wire Format Sizes ===");
+        println!("KeyPackage:        {} bytes", kp_bytes.len());
+
+        // 2. Create group (no wire message, just local state)
+        creator.create_group(b"size-test").expect("create group");
+
+        // 3. Add member -> Commit + Welcome
+        let (commit_bytes, welcome_bytes) = creator.add_member(&kp_bytes).expect("add member");
+        println!("Commit (add):      {} bytes", commit_bytes.len());
+        println!("Welcome:           {} bytes", welcome_bytes.len());
+
+        // Join the group
+        joiner.join_group(&welcome_bytes).expect("join");
+
+        // 4. Application message (short payload)
+        let short_msg = creator.send_message(b"hello").expect("short msg");
+        println!("AppMessage (5B):   {} bytes", short_msg.len());
+
+        // 5. Application message (medium payload ~100 bytes)
+        let medium_payload = vec![0x42u8; 100];
+        let medium_msg = creator.send_message(&medium_payload).expect("medium msg");
+        println!("AppMessage (100B): {} bytes", medium_msg.len());
+
+        // 6. Self-update proposal
+        let update_proposal = creator.propose_self_update().expect("update proposal");
+        println!("UpdateProposal:    {} bytes", update_proposal.len());
+
+        // Joiner processes the proposal
+        joiner.receive_message(&update_proposal).expect("recv proposal");
+
+        // 7. Commit (update only, no welcome)
+        let (update_commit, _) = joiner.commit_pending_proposals().expect("commit update");
+        println!("Commit (update):   {} bytes", update_commit.len());
+
+        // Summary for LoRa feasibility
+        println!("\n=== LoRa Feasibility (SF12/BW125, MTU=51 bytes) ===");
+        println!("KeyPackage:        {} fragments ({:.0}s at 1% duty)",
+            (kp_bytes.len() + 50) / 51,
+            (kp_bytes.len() as f64 / 51.0).ceil() * 36.0 / 60.0);
+        println!("Welcome:           {} fragments ({:.0}s at 1% duty)",
+            (welcome_bytes.len() + 50) / 51,
+            (welcome_bytes.len() as f64 / 51.0).ceil() * 36.0 / 60.0);
+        println!("AppMessage (5B):   {} fragments",
+            (short_msg.len() + 50) / 51);
+
+        // Assertions to catch regressions / validate estimates
+        assert!(kp_bytes.len() < 1000, "KeyPackage should be under 1KB");
+        assert!(welcome_bytes.len() < 3000, "Welcome should be under 3KB");
+        assert!(short_msg.len() < 300, "Short AppMessage should be under 300B");
+    }
+
+    /// Measure MLS sizes with hybrid (post-quantum) mode enabled.
+    #[test]
+    fn measure_mls_wire_sizes_hybrid() {
+        let creator_id = Arc::new(IdentityKeypair::generate());
+        let joiner_id = Arc::new(IdentityKeypair::generate());
+
+        let mut creator = GroupMember::new_hybrid(Arc::clone(&creator_id));
+        let mut joiner = GroupMember::new_hybrid(Arc::clone(&joiner_id));
+
+        // KeyPackage with hybrid (X25519 + ML-KEM-768) init key
+        let kp_bytes = joiner.generate_key_package().expect("generate hybrid KP");
+        println!("=== MLS Wire Format Sizes (Hybrid PQ Mode) ===");
+        println!("KeyPackage (PQ):   {} bytes", kp_bytes.len());
+
+        creator.create_group(b"hybrid-size-test").expect("create group");
+        let (commit_bytes, welcome_bytes) = creator.add_member(&kp_bytes).expect("add member");
+        println!("Commit (add, PQ):  {} bytes", commit_bytes.len());
+        println!("Welcome (PQ):      {} bytes", welcome_bytes.len());
+
+        joiner.join_group(&welcome_bytes).expect("join");
+
+        let short_msg = creator.send_message(b"hello").expect("short msg");
+        println!("AppMessage (PQ):   {} bytes", short_msg.len());
+
+        // PQ KeyPackages are larger due to ML-KEM-768 public key (1184 bytes)
+        assert!(kp_bytes.len() > 1000, "Hybrid KeyPackage should be >1KB due to ML-KEM");
+        assert!(kp_bytes.len() < 3000, "Hybrid KeyPackage should be <3KB");
+    }
 }

crates/quicprochat-p2p/src/envelope.rs

@@ -375,4 +375,63 @@ mod tests {
         let result = MeshEnvelope::from_wire(&garbage);
         assert!(result.is_err(), "garbage input must return Err, not panic");
     }
+
+    /// Measure MeshEnvelope overhead for various payload sizes.
+    /// This informs constrained link feasibility planning.
+    #[test]
+    fn measure_mesh_envelope_overhead() {
+        let id = test_identity();
+        let recipient = [0xAAu8; 32];
+
+        println!("=== MeshEnvelope Wire Overhead (CBOR) ===");
+
+        // Empty payload
+        let env_empty = MeshEnvelope::new(&id, &recipient, vec![], 3600, 5);
+        let wire_empty = env_empty.to_wire();
+        println!("Payload   0B: wire {} bytes (overhead: {} bytes)", wire_empty.len(), wire_empty.len());
+        let base_overhead = wire_empty.len();
+
+        // 1-byte payload
+        let env_1 = MeshEnvelope::new(&id, &recipient, vec![0x42], 3600, 5);
+        let wire_1 = env_1.to_wire();
+        println!("Payload   1B: wire {} bytes (overhead: {} bytes)", wire_1.len(), wire_1.len() - 1);
+
+        // 10-byte payload ("hello mesh")
+        let env_10 = MeshEnvelope::new(&id, &recipient, b"hello mesh".to_vec(), 3600, 5);
+        let wire_10 = env_10.to_wire();
+        println!("Payload  10B: wire {} bytes (overhead: {} bytes)", wire_10.len(), wire_10.len() - 10);
+
+        // 50-byte payload
+        let env_50 = MeshEnvelope::new(&id, &recipient, vec![0x42; 50], 3600, 5);
+        let wire_50 = env_50.to_wire();
+        println!("Payload  50B: wire {} bytes (overhead: {} bytes)", wire_50.len(), wire_50.len() - 50);
+
+        // 100-byte payload (typical short message)
+        let env_100 = MeshEnvelope::new(&id, &recipient, vec![0x42; 100], 3600, 5);
+        let wire_100 = env_100.to_wire();
+        println!("Payload 100B: wire {} bytes (overhead: {} bytes)", wire_100.len(), wire_100.len() - 100);
+
+        // Broadcast (empty recipient) - saves 32 bytes
+        let env_bc = MeshEnvelope::new(&id, &[], b"broadcast".to_vec(), 3600, 5);
+        let wire_bc = env_bc.to_wire();
+        println!("Broadcast 9B: wire {} bytes (no recipient)", wire_bc.len());
+
+        println!("\n=== LoRa Feasibility (SF12/BW125, MTU=51 bytes) ===");
+        println!("Empty envelope:    {} fragments", (wire_empty.len() + 50) / 51);
+        println!("10B payload:       {} fragments", (wire_10.len() + 50) / 51);
+        println!("100B payload:      {} fragments", (wire_100.len() + 50) / 51);
+
+        // Baseline overhead is fixed fields:
+        // - id: 32 bytes
+        // - sender_key: 32 bytes
+        // - recipient_key: 32 bytes (or 0 for broadcast)
+        // - signature: 64 bytes
+        // - ttl_secs: 4 bytes
+        // - hop_count: 1 byte
+        // - max_hops: 1 byte
+        // - timestamp: 8 bytes
+        // Total fixed: ~174 bytes raw, CBOR adds ~5-10% overhead
+        assert!(base_overhead < 200, "Base overhead should be under 200 bytes");
+        assert!(base_overhead > 150, "Base overhead should be over 150 bytes (sanity check)");
+    }
 }